1. If new engine is being installed, transfer mounting brackets and insulators, generator, power steering pump, A/C compressor, drive plate (flywheel), turbocharger, and necessary mounting brackets, shields, damper pulleys, sensors and fittings, from old to new engine.
2. Attach lifting bracket to engine.
3. Attach hoist to lifting bracket. Raise engine and guide it into engine bay with aid of helper.
4. Align and seat engine on transmission. Be sure converter pilot hub is seated in crankshaft and that transmission is seated on engine block dowels. Install 2-3 transmission attaching bolts (finger tight) to hold engine and transmission in place.
5. Align and seat engine mounting bracket insulators on frame brackets. Be sure insulator studs are fully seated in frame brackets before proceeding.
6. Apply Loctite 242 to transmission, converter, and engine mount nuts/bolts. Then install and tighten nuts and bolts to following torque:
• Converter bolts to 32 lb-ft (43 N•m)
• Transmission bolts to 35 lb-ft (47 N•m)
• Insulator stud nuts to 90 lb-ft (122 N•m)
7. Install converter housing access cover. Tighten cover attaching screws to 60 lb-in. (7 N•m) torque.
8. Connect engine oil cooler lines to fittings at rear of engine block.
9. Install turbocharger.
10. Install starter motor and shield with aid of helper. Tighten
starter mounting bolts to 30-40 lb-ft (41-54 N•m) torque. Do
not connect cable and solenoid wire to starter at this time.
11. Install exhaust pipe and heat shield, if removed and connect exhaust pipe to turbocharger. Tighten attaching nuts to 37 lb-ft (50 N•m) torque.
12. Install new oil filter.
13. Install intake manifolds and crossover.
14. Install/connect following:
• Wire harness brackets and clamps
• Injection pump, engine harness, sensor wires
• Turbocharger actuator vacuum hose
• Torbocharger heat shield
• Transmission and engine dipstick tubes
• AMG engine harness
15. Install fuel pump in clamp at driver side of engine bay.
16. Connect fuel lines to injection pump.
17. Install CDR valve and hose if removed.
18. Route hydraulic lines from power steering pump to hydro boost unit and connect lines. Be sure lines are clear of hot or rotating components and are not kinked at any spot.
19. Remove protective tape from A/C suction/discharge hose adapter and connect it to compressor. Install new seal washers.
20. Connect glow relay cable and wires.
21. Position support on back of alternator. Then install generator, mounting bracket, idler pulley, support, and tensioner assembly.
22. Position remaining cables for battery installation.
23. Connect heater hoses to water pump and water crossover.
Mount idler pulley on generator bracket.
24. Install fan and clutch assembly.
25. Install serpentine belt.
26. Connect air inlet hose to turbocharger.
27. Attach radiator upper hoses and tube to thermostat housing.
28. Connect battery positive cable and solenoid wire to starter motor.
29. Position radiator, shroud, condenser, and oil cooler assembly on frame and between air lift brackets, with aid of helper. Then secure assembly and supports to frame and air lift brackets. Tighten support bolts to 26 lb-ft (35 N•m) torque. Tighten frame mount bracket bolt to 30 lb-ft (41 N•m) torque.
NOTE: Verify that fan-to-shroud clearance is at least 1/4 inch
(3.18 mm) at all points around shroud before proceeding.
Loosen bolts and adjust position if necessary.
30. Connect radiator upper and lower hoses.
31. Connect surge tank hose to radiator.
32. Install return lines onto power steering pump.
33. Connect power steering pump return lines to oil cooler.
34. Remove protective wrapping or caps and connect hoses to A/C condenser and oil coolers. Use new O-rings on cooler and A/C hoses (Figure 2-61).
35. Install passenger and driver side splash shields.
36. Install battery tray and batteries. Connect positive and negative cables to batteries.
37. Install seals and cover plates on air lift brackets. Notched side of seals face engine.
38. Refill engine cooling system, refill engine crankcase with recommended oil, and top off transmission and power steering fluids.
39. Evacuate A/C system for 30 minutes, and recharge.
40. Leak check A/C system.
41. Start and run engine. Bleed injectors at line fittings if necessary. Then stop engine, recheck coolant and lubricant levels, and add as necessary.
42. Bleed cooling system with air bleeds on engine and radiator.
43. Test drive vehicle and check for leaks or vibrations.